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30″ SaferCut®

The Everett SaferCut® 30”/762 mm diameter wheel, 50HP (37.5kW) semi-automatic, dry abrasive cutoff saw is designed for production cutting of round solids to 8” (203mm) per the specifications set forth below. Its failsafe PLC controls the cutting action through an operator controlled proportional-directional hydraulic system. Detailed specifications as well as standard and optional features of the basic machine follow.

Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Up to

10"

Solids

5"

Shapes

Highly Productive Solution

The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is designed, tooled, and programmed for production-cutting and when combined with part handling and positioning accessories set forth below, it can be the center of an automated, productive cell. Highly trained and skilled operators are not required and that fact was carefully considered when we designed the health and safety aspects of this production cutting system.

Watch SaferCut® In Action

Features

The saw is built on a structural weldment with integral fork pockets. The saw head and work holding devices are aligned on a ground top plate mounted to the base. An internal spark arrester baffle decelerates sparks and allows them to fall into the included debris cart integral to the base. Dust and smoke flow freely around the baffle into the optional dust collector or into your central system. The compact design minimizes required floor space.

The saw head is designed for cutting with a nominal 30”/762mm diameter abrasive wheel at up to 14,200sfm or 72m/sec wheel speed (Vc). The saw’s rocker arm is a heavy steel member, heat treated, and is precision machined for the crucial bearing-to-trunnion shaft alignment that provides for straight, vertical cuts. The rocker arm pivots on a trunnion stand that also acts as the oscillation pivot arm. The structural aluminum castings are T6 heat treated for stiffness and long life. It is a time-proven design that has survived field testing and has contributed to the Severit-with-Everett reputation for reliability for over 62 years.

The 2,625-rpm rated main wheel spindle drives the 8.5” (305mm) cast iron wheel flange. The abrasive cutoff wheel is mounted on a 1.75” (44.5mm) arbor shaft and clamped by the outer wheel flange. The wheel flanges are assembled on the shaft and faced and trued as an assembly for balance and straightness. The inner wheel flange is equipped with a 0.437” (11mm) diameter drive pin on a 5.5” (140mm) bolt circle diameter. The wheel spindle is self-contained, fully protected with labyrinth seals and held in the housing with a precision, bolt-in cap for ease or repair/replacement as shown above.

A 50HP/37.5 kW induction motor is standard. Standard spindle motor speed is 1725RPM (11,800sfm/56m/s) operating with across the line starters. Motor control system also includes a stand-alone “zero-speed” safety monitoring relay. If the optional Sinamics VFD is purchased, wheel speed would typically be 14,200sfm/71m/s. Drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”) and other safety-related functionality. Saw head is equipped with precision inclinometer to enable wheel diameter tracking based on cut start position. With known wheel diameter, control will adjust the wheel RPM to maintain a constant peripheral wheel speed. The drive and PLC monitor cutting power and actual wheel speed and abort overly aggressive cuts to protect the operator and machine. The VFD also allows for dynamic wheel braking to stop the wheel in 3 seconds for fast part-to-part changes as the doors will not unlock until the safety system detects zero-wheel speed…which can take 30-50 seconds without motor braking.

With the VFD data monitoring capabilities, the saw motor control system provides your operator process feedback in real time to protect the operator, wheel, work, and saw from overly aggressive cutting. A LED indicator flashes colored and audible codes during the cutting cycle. Green for a moderate process (<80% of drive current use), yellow/magenta during moderately aggressive cutting (>80% but less than 100%) and red for very aggressive cutting (>100%). This feedback helps train the operator to use the power available for fast cutting cycles, but not so much as to shorten the life of the saw and motor…or to shatter the wheel and damage the work or machine.

The saw head is equipped with an oscillating trunnion stand that, program-dependent, can oscillate the wheel front to back during the cut. The oscillator is driven by a motor and gearbox that, when active in the cutting setup, moves the wheel forward and backward, relative to the work piece centerline, approximately 3/8” (10mm) which reduces the effective length of wheel contact, provides for chip evacuation, and cools the cut. Generally, for cuts where the material cross section is greater than 4.7” (≥5% of wheel periphery), oscillation should be used in the cutting process.

The saw head is fed through the cut by the same industrial-duty hydraulic cylinder (equipped with extremely abrasive environment seals) that has made Everett powerhead saws known for reliability. The hydraulic system (not air-over-oil) is controlled by an appropriately sized power unit complete with positive displacement pump, reservoir, pressure relief, proportional-directional valve, proportional down-feed pressure override valve, and associated control switches and safety valving. The power unit also controls hydraulic work clamping, if so equipped.

Standard work holding designed for bar and tube applications is shown below. A cast aluminum v-block supports 8 replaceable wear surfaces. A pneumatically actuated chain wraps over the bar and hooks into the front side of the vise.

The saw system’s motors, hydraulics, operations, and ladder logic are controlled by a failsafe PLC and associated failsafe I/O cards. The main spindle motor is controlled by the VFD with dynamic braking. Braking is important for productivity since the door interlocks will not unlock until the zero-speed safety relay detects that the wheel is no longer spinning. Hydraulic motion is coordinated by the PLC through a proportional-directional valve as commanded by the PLC and operator-controlled potentiometer.

This is a production saw designed to promote injury-free operations in a modern manufacturing environment. The system is designed to adhere to the best functional safety practices (ISO13849) and to be EN Machinery Directive compliant based on a formal risk assessment to ISO12100. The safety systems were designed based on a detailed and comprehensive formal risk assessment. The vice clamps and cutting area are fully protected in the interlocked machine enclosure for safety and to contain smoke and debris. Easy access, interlocked doors allow for easy wheel change and clean up yet protect your operator from the common dangers of an open, tool room chop saw originally designed for highly skilled operators. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or if the wheel is turning. Cycle start and power work clamping, if so equipped, requires two-handed control for operator safety.

Specifications

Maximum Workpiece Diameter

8” (203.2mm)

Minimum Workpiece Diameter

1” (25.4 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

4” (100mm)

Typical Inconel Cutting Speed (<4.5” diameter) Dry

2 sec/square in

Typical Inconel Cutting Speed (>5.5” diameter) Dry

5 sec/square in

Wheel Spindle Power

50 hp (37.5kW)

Wheel Peripheral Speed (if wheels rated accordingly)

14,200 sfm (72 m/s)

Wheel Flange Drive Pin (Diameter, Bolt Circle)

0.625”, 3” (15.9, 75mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

50 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

2,500 lbs

Machine Dimensions

50” W x 72” D (1.3m x 1.8m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

30” (762 mm)

Width

0.230” (5.8 mm)

Bore

1.75” (44.5 mm)

SaferCut® Products

10’’ SaferCut®

Wheel Spindle Power

3HP

Cut Capacity

2.5″

New Wheel Cut Clearance

3.75″

16’’ SaferCut®

Wheel Spindle Power

20 hp (7.5-15kW)

Maximum Economical Capacity

3″

New Wheel Cut Clearance

6″

20’’ SaferCut®

Wheel Spindle Power

20 hp (15kW)

Maximum Economical Capacity

4.5″

New Wheel Cut Clearance

7″

26’’ SaferCut®

Wheel Spindle Power

40/50 hp (30-37.5kW)

Maximum Economical Capacity

7″

New Wheel Cut Clearance

8.75″

30’’ SaferCut®

Wheel Spindle Power

50 hp (37.5kW)

Maximum Economical Capacity

8″

New Wheel Cut Clearance

10.75″